Sheet product/pouch systems and methods for producing them

ABSTRACT

A sheet product/pouch system (such as a packaged two-ply sticker product) made by a process wherein individual sheets of a sheet product are cut from a continuous web before said individual sheets are provided with a bottom pouch layer (or a top pouch layer). The edges of the bottom pouch layer and top pouch layer are joined to create a pouch or package for the sheet product. An edge of the resulting pouch is provided with a perforation line to facilitate opening said pouch in order to gain access to the sheet product.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to packaged sheet products such as those propylene or cellophane®-wrapped packages that contain sticker, label or decorative craft items. This patent disclosure is especially concerned with continuous production of those packaged sheet product/pouch systems that comprise (1) a top pouch layer, (2) a two-ply sheet product comprised of an upper sheet product layer (having decorative pre-cut figures whose underside is provided with a releasable adhesive) and a lower sheet product layer (having an adhesive release layer on its top side) and (3) a bottom pouch layer. The upper sheet product layer and the lower sheet product layer adhere (in registry) to each other at their interface to create a unified two-ply sheet product. The top pouch layer and the bottom pouch layer are affixed to each other at their respective edges in order to form a pouch which packages the sheet product.

[0003] 2. Description of the Prior Art

[0004] Sheet products are often enclosed in protective pouches, bags, wrappers, etc. by placing a sheet product web (i.e., a roll of sheet product material) on a production line wherein two packaging material webs (made of clear, or semi-clear, pouch-forming materials such as propylene, cellophane® and the like), are respectively placed over and under the sheet product web. The two packaging material sheets are then sealed around their edges in order to form a protective pouch around the sheet product. These prior art manufacturing methods eventually came to be regarded as being ineffective and/or inefficient in that many thin-bodied sheet products had to be individually provided with a separate and distinct sheet of cardboard as a “backer” sheet in order to assure proper enclosure of each sheet product in its pouch or package. The individual cardboard sheet provided the body or rigidity needed to prevent the edges of a flattened, thin-bodied sheet product from curling inward when the pouch was created by sealing (e.g., heat sealing, adhesive sealing, etc.) the top pouch layer to the bottom pouch layer. These cardboard backer sheets are not web type products (i.e., they are not dispensed from a roll of feedstock mounted on a reel). Hence, they are introduced into an otherwise continuous production process as separate and distinct flat sheets. Such introduction of those individual cardboard sheets into an otherwise continuous manufacturing process caused various operating inefficiencies.

[0005] U.S. Pat. No. 4,841,712 (“the '712 patent”) sought to improve upon the above-described prior art methods for producing sheet product/pouch systems. Among other things, the methods of the '712 patent eliminated the need for the presence of a separate and distinct “backer” sheet of cardboard in the final product package. FIG. 1 of the present patent application generally describes the manufacturing methods taught by that patent. These methods begin when a reel dispenses a continuous web of a sheet product feedstock. This web may be comprised of an upper sheet product layer and a lower sheet product layer joined at their interface by an adhesive material to produce a two-ply sheet product web. More specifically, these two-ply sheet product webs are comprised of (1) an upper sheet product layer whose bottom side is provided with a layer of releasable adhesive and (2) a lower sheet product layer whose top side is provided with an adhesive release layer that facilitates release of “sticker” items that are subsequently cut into the body of the upper sheet product layer. The sheet product web shown in FIG. 1 then passes through a printer. Thereafter, the bottom of the sheet product web is placed in pressured contact with a bottom pouch layer carrier web material that also is continuously dispensed from a reel. The top surface of this bottom pouch layer carrier web includes an adhesive coating. Thus the adhesive coating on the top surface of the bottom pouch layer carrier web adheres to the bottom side of the sheet product web when the two webs are forced into contact with each other by a roller system. Thereafter, a top pouch layer carrier web is placed over the sheet product web.

[0006] It might also be noted here that the '712 patent uses the word “sheet” to describe the bottom pouch layer carrier web. The same terminology is used to describe the system's top pouch layer web as well. However, all of the drawings of that patent clearly show that both “sheets” are in fact a continuous sheet or web—as opposed to being a series of individual sheets. Thus, the word “sheet” used to describe the bottom pouch layer (and the top pouch layer) in the '712 patent text should be interpreted to mean a continuous sheet (i.e., a “web”) rather than a series of individual sheets. Both the bottom pouch layer web and the top pouch layer web of that patent disclosure remain in their respective continuous web forms until they are laterally cut by a cutter device near the end of the therein described manufacturing process. In effect, the lower sheet product layer shown in FIG. 1 remains in a “continuous” form (and in a continuous state of tension) between the left guide roller and cutter device. This point is emphasized because it constitutes a major distinction between applicant's invention, and the apparatus and methods described in the '712 patent.

SUMMARY OF THE INVENTION

[0007] The present invention seeks to improve upon all such prior art methods for manufacturing premium product/pouch systems. This invention also seeks to improve the premium product/pouch systems themselves—especially with respect to how they are opened by the consumer. These improvements are economic, practical and esthetic in nature. Like the production methods described in the '712 patent, the present invention involves continuous, on-line production of sealed protective pouches that package premium objects e.g., two-ply sticker-carrying sheets, baseball cards, small toys, single ply sheet products and the like—without the need for individual handling of those premium objects, and without the need for a cardboard backer sheet in the end product package. In the more preferred embodiments of applicant's invention, the subject premium objects are sheet-like in nature. Such sheet-like components of applicant's sheet product/pouch systems may have one or more (e.g., 2 or 3) layers or plys. An example of a single layered sheet product might be a single layered sheet upon which a calendar, baseball card, picture, poster and the like is printed. However, in the most preferred embodiments of this invention, the sheet products are two-ply sheets, and especially those having so-called craft “sticker” items cut into their upper layer. The resulting cut design(s) can be pulled from the upper sheet product layer by human fingers.

[0008] The present invention differs from the teachings of the '712 patent because applicant has found that, among other things, improved operating advantages in the production of packaged premium products, and especially two-ply sheet product/pouch products, can be obtained if a sheet product web feedstock is cut into separate and distinct sheets before the resulting individual sheet products are associated with either an underlying bottom pouch layer, or an overlying top pouch layer. The preferred final products of the manufacturing methods described in the present patent disclosure also are characterized by the fact that their final sheet products are enclosed in a sealed protective pouch that can be readily opened without the need for sharp instruments such as knives or scissors. This feature is noteworthy in view of the fact that sheet product/pouch systems of the type described herein are very often used by young children.

[0009] Next, it might be noted that two-ply sticker sheets will be used to illustrate this invention, even though said invention may employ one, two, three ply, etc. sheet products. It also should be noted that the pouch material(s) in which applicant's individual premium products are packaged will typically be clear (plain or colored) propylene sheet material(s), clear cellophane® sheet material(s) and/or other comparable clear packaging materials. In any case, applicant's pouch or package will include a top layer or sheet of such a clear packaging material that creates a top surface of the overall end product or package. The top pouch layer also serves to define a top sealing zone that extends marginally outwardly beyond the edges of a premium item to be packaged. Similarly, a bottom pouch layer is positioned under the bottom side of such a premium product. This bottom pouch layer surrounds the bottom of the premium product and, like the top pouch layer, extends marginally outwardly beyond the bottom edges of the premium product to be packaged. The respective extended edges of the top and bottom pouch layers are then joined to create a seal that marginally surrounds and packages the subject premium product. For example the respective extended edges of the top and bottom pouch layers can be joined through use of an adhesive or through use of known heat sealing operations. Preferably, at least one of the top and bottom edges of the top and bottom pouch layers will be perforated (in ways hereinafter more fully described) to facilitate opening applicant's final product packages on one or more of its four sides. Moreover, the top and bottom pouch layers may be provided with holes to receive wire-like store display hanger systems.

[0010] By way of a more detailed example of the manufacturing methods and final products of the present invention, applicant notes that one particularly preferred method begins when a sheet product web is removed from a feed reel and then pressure rolled to produce a flat contour in said web. This sheet product web also is placed in a first state of tension. The top or “display” side (i.e., the main design, artwork, information-carrying side) of the sheet product web then receives printing from a printer device. Such printers are typically multicolor printers such as those that employ cyan, yellow, magenta and black ink coloring systems. The bottom side of the web may also receive printing (e.g., printing that imparts technical information, business information regarding the source of the goods, logos, advertisements and the like). Regardless of the nature of the ink coloring system, or the information conveyed by it, applicant's printing operation is carried out while the sheet product web is in a first state of tension. In the case of a two-ply “sticker” type product, the top side of the upper sheet product layer normally receives printing that includes one or more designs whose outer edges are also defined by a cut out border that forms the contour or shape of one or more sticker pieces. The cutting of such designs, borders, contours, etc. preferably takes place after the printing operation.

[0011] Thereafter, applicant's sheet product web is laterally cut into separate and distinct sheets before said sheets are associated with either a bottom pouch layer, or a top pouch layer. Again, this lateral cutting of the product sheet web constitutes a major distinction between the manufacturing process of the present patent invention and the process disclosed in the '712 patent. It might also be noted here that applicant's complete, lateral cutting of the sheet product web feedstock is “counterintuitive” to the thinking of those skilled in this art because of their strong desire to keep any given web in tension in order to assure registry of all webs passing through a continuous manufacturing process. Applicant's system, in effect, loses this desired sheet product web tension when said web is completely cut.

[0012] After being cut from the sheet product web, each resulting individual sheet product is guided into a first downstream sheet-handling system (e.g., roller system) that helps carry out further operations in the overall manufacturing process. In one particularly preferred embodiment of this invention, an air stream is directed at the bottom side of each cut sheet product in order to accurately deliver said sheet to the downstream sheet handling system. In any case, the first downstream sheet handling system serves to maintain each succeeding sheet that is cut from the sheet product web in a flat contour so that it can fully abut with the top side of a bottom pouch layer material. In another particularly preferred embodiment of this invention, the top side of a bottom pouch layer is provided with an adhesive coating that causes the bottom pouch layer to adhere to the bottom of the sheet product layer. In yet another preferred embodiment, a downstream roller system into which each individual cut product sheet is fed is also the same roller system that serves to place the bottom pouch layer web in contact with the bottom side of each individual cut product sheet. Thereafter, a second, further downstream, roller system (acting in conjunction with the first downstream roller system) begins a process of placing the resulting individual sheet/bottom pouch layer web in a second state of web tension employed in the process. In still other particularly preferred embodiments of this invention, this second state of tension is produced by roller systems having rollers provided with “enlarged” radius dimensions for reasons, and in ways, hereinafter more fully described.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013]FIG. 1 is a schematic side view of a prior art apparatus and method used for producing sheet product/pouch systems.

[0014]FIG. 2 is a schematic side view of the apparatus and method for producing sheet product/pouch systems according to the teachings of the present patent disclosure.

[0015]FIG. 3 is a perspective view of a portion of the apparatus and method depicted in FIG. 2 that is concerned with providing a sheet product with a bottom pouch layer.

[0016]FIG. 4 is a perspective view of another portion of the apparatus and method depicted in FIG. 2 that is concerned with providing a sheet product with a top pouch layer.

[0017]FIG. 5 is a plan view of a top pouch layer/sheet product/bottom pouch layer web used in the practice of the present invention.

[0018]FIG. 6 is a cut-away side view of the web shown in FIG. 5, as seen across section A-A.

[0019]FIG. 7 is a plan view of a sheet product/pouch system produced by the apparatus and methods of the present invention showing the location of various store display holes, edges and cutting operations that are associated with the overall sheet product/pouch systems of this patent disclosure.

[0020]FIG. 8 is a plan view of a finished product produced by the present invention being opened through use of a pouch perforation system.

DETAILED DESCRIPTION OF THE DRAWINGS Prior Art

[0021]FIG. 1 depicts a prior art sheet product/pouch manufacturing method 10 of the type generally disclosed in the '712 patent. This method 10 produces individual sheet product/pouch products 12. These products generally comprise a final sheet product 14 in a pouch or package 16. The overall apparatus that carries out this prior art method 10 includes a product sheet web dispensing reel 18, web guide roller 20, conventional flexographic printer 22, carrier web dispensing reel 24, carrier-web engagement rollers 26, die cutter 28, anvil roller 30, matrix stripping roller 32, matrix scrap takeup reel 34, top web dispensing reel 36 and a pair of top web flattening rollers 38. This sheet product/pouch manufacturing method 10 also employs a top web edge/bottom web edge sealer 40, cutter 42, and premium item collection rack 44. It also should be noted that at least the lower layer of the sheet product web 46 remains in a substantially continuous state of tension over a distance 17 that generally extends from guide roller 20 to cutter 42.

[0022] The sheet product web 46 depicted in FIG. 1 is shown having a top layer 46T and a bottom layer 46B. The top surface 52 of the top layer 46T is preferably coated to facilitate printing thereon by printer 22. The bottom surface 53 of the bottom layer 46B may be similarly coated to facilitate printing there as well. The printer 22 may print on the top 46T of the sheet product web 46 and/or its bottom 46B with desired indicia, images, decorations and the like in order to form a print-carrying sheet product. In any case, the sheet product web 46 preferably includes a releasable adhesive layer 54 composed of a conventional pressure sensitive adhesive. FIG. 1 also shows how the sheet product web 46, a lower pouch layer 48 and a top pouch layer 50 are respectively introduced into the overall manufacturing process in the form of continuous webs that are, respectively, adhesively affixed to at least one other component of the overall product sheet/pouch system. For example, the bottom surface 53 of the bottom layer 46B of the continuous web 46 is physically associated with a continuous web 48 of a propylene, cellophane®, etc. packaging material that forms the bottom pouch layer of a given resulting end product package or premium item 12. This physical association follows from the fact that the top surface 56 of the bottom pouch layer web 48 is provided with an adhesive material 58. Similarly, the sheet product web 46 receives a top layer of propylene, cellophane®, etc. packaging material that is likewise dispensed from a dispenser reel 36 in the form of a web 50. This web 50 is associated with the adhesive 58 on the edges of the bottom pouch layer that marginally extend beyond the edges of the sheet product (e.g., beyond the edges of a two-ply, sticker-containing sheet product).

[0023] In any case, after the printing operation, the bottom pouch layer web 48 is adheringly affixed to the bottom surface of the bottom of the lower sheet product layer 46B. To this end, the bottom pouch layer web 48 presents a top surface 56 which includes the above-noted adhesive coating 58. Engagement rollers 26 place the sheet product web 46 and bottom pouch layer web 48 in abutting contact with one another so that top surface 56 of the bottom pouch layer is forced to adhere to the lower surface of the bottom layer 46B of the sheet product web 46. As part of this process, the sheet product web 46 and the bottom pouch layer web 48 continuously pass between die cutter 28 and anvil roller 30 so that said die cutter 28 can cut through the top sheet product layer 46T in order to produce the desired, spaced-apart, cut out designs or “stickers”. These designs are surrounded by a waste matrix 60. A waste matrix take-up reel 34 continuously removes this waste matrix 60 via a matrix stripping roller 32 which is in contact with the top surface of the now die cut sheet product web 46.

[0024] After removal of the waste matrix 60, various spaced apart sheet product items 14 remain in adhered contact with the lower sheet product layer 46B. FIG. 1 illustrates how removal of the waste matrix 60 exposes certain portions of the top surface 56 and certain portions of the adhesive coating 58 of the bottom pouch layer 48. These portions marginally and continuously surround each premium object 14. These exposed portions thus present a plurality of carrier sealing zones 62 that respectively surround each premium object 14. The carrier sheet 48, with premium objects 14 adhering thereon, then passes into a top-carrier laminating roller system 38. Here, a sheet of top pouch layer web 50 is placed over the premium objects 14. A top sheet dispensing reel 36 is shown continuously dispensing the top sheet web 50 to the top-carrier laminating rollers 38. These rollers 38 place the top sheet web 50 in abutting contact with the upper surface of successive premium objects 14 and with successive sealing zones 62. The '712 patent also teaches that the top sheet 50 is normally of the same width as the carrier sheet 48 and thereby presents a corresponding plurality of top sheet sealing zones 64 whose edges correspond with the edges of the carrier sealing zones 62. It also should be appreciated that the continuous tension employed over the distance 17 between the roller 20 and the cutter 42 of this manufacturing process is needed to keep the two equally wide packing webs in the desired edge alignment or registry.

[0025] The rollers 38 place the top sheet sealing zones 64 in abutting contact with carrier sealing zones 62. These two zones adhere together owing to the presence of the adhesive layer 58 on the top 56 of the carrier web 48. Sealing zones 62 and 64 thereby form a plurality of corresponding sealed zones 66 continuously and marginally surrounding each premium object 14. Carrier web 48 and top web 50 are then joined at sealed zones 66, and thereby form an assembly 68 of end product premium items 12 that each include a sealed protective pouch 16 and a premium object 14 enclosed therein. A cutter 42 then separates each succeeding premium item 12 from the assembly 68 by laterally cutting completely through the carrier sheet 48 and the top sheet 50 about midway between each premium object 14. The separated premium product items 12 then are directed into a collection rack 48 or, in the alternative, onto a conveyor system (not shown).

[0026] The '712 patent also teaches an alternative process wherein the cutter 42 makes centrally disposed tear slits 70 at the juncture between successive premium items 12. These tear slits 70 preferably extend into the sealed zones at the opposed ends of each premium item 12. The cutter 42 can also be used to cut lateral perforations to act as tearable connections between each end product premium item 12—as opposed to completely separating them from assembly 68. In this way, the assembly 68 can be formed into a self-wound roll from which individual premium items 12 can be torn—if this is the desired merchandizing form for the final product.

Present Invention

[0027]FIG. 2 is a schematic side view of applicant's overall manufacturing method 100. It is shown in an embodiment that is particularly adapted to produce sheet product/pouch systems. For example, the sheet products of the present invention can be in the nature of the previously described two-ply “sticker” sheets. Those skilled in this art will appreciate that such sticker sheets are often sold in “theme” packages. Such themes may, for example, relate to crafts (e.g., photo album creation), sports, fashion, education, games and the like. Such sheet products are very often sold as children's toys, craft and/or entertainment items. There are, however, many other possible uses for applicant's sheet product/pouch systems. For example, manufacturers of packaged food products such as cereals often include premium items such as coupons, baseball cards, and so forth in the food package as part of a prize, premium and/or merchandising program. In such cases, such items must be enclosed in a sealed, protective pouch so that they do not come into direct contact with the food product.

[0028] Be that as it may, FIG. 2 depicts a sheet product web 102 being dispensed from a dispenser reel 104 as the first part of a sheet product/pouch system manufacturing process. By way of example only, the sheet product web 102 is depicted as being a two-ply web comprised of an upper sheet product layer 106 and a lower sheet product layer 108. After passing over a roller 110 (e.g., a guide roller, ironing roller, etc.) the sheet product web 102 passes through a printer 112. The printer 112 will preferable (but not necessarily) be capable of printing on both the top side 114 of the upper sheet product layer 106 and the bottom side 116 of the lower sheet product layer 108. Thereafter, an array of designs are cut into the upper sheet product layer 106. To this end, a cutting system having a die cutter roller 118 and a cooperating anvil roller 120 are shown creating a nip through which the sheet product web 102 passes. The die cutter roller 118 is shown provided with a die component 122 having a depth 124 that is substantially the same as the thickness of the upper sheet product layer 106. Thus, the desired sticker designs are cut in the upper sheet product layer 106—and not in cut in the lower sheet product layer 108. The die cutter roller 118 may be (and preferably is) further provided with a second, third, etc. die that cuts edge portions (e.g., side edges and/or top and bottom edges) from the upper sheet product layer to define the final sheet product's size (length and/or width). These cutting operations will produce scrap products that can be removed from the process in ways hereinafter more fully described.

[0029] The sheet product web 102 is then conveyed to a second cutter system having a die roller component 126 that is provided with a die 128 having a depth 130 that is at least the combined thickness of the upper sheet product layer 106 and the lower sheet product layer 108. This die roller component 126 cooperates with an anvil roller component 127 in ways well known to the sheet cutting arts. In short, the die 128 of this cutter system should be capable of completely cutting through the entire sheet product web 102. The cut made by the die 128 is a lateral cut (cut normal to a sheet product edge) that serves to completely separate each succeeding sheet from the preceding portion of the sheet product web 102. Thus, the present method for making sheet product/pouch systems differs from the methods disclosed in the '712 patent in that applicant's sheet product is completely severed from the web 102 before that sheet is associated with either a bottom pouch layer or a top pouch layer.

[0030] It also should be noted that the sheet product web 102 receives (1) printing in printer 112, (2) design item-creating die cutting by die 122 and (3) lateral cutting by die 128 while the web 102 in a first general state of tension T₁ that generally exists over the distance 132 between roller 110 and lateral cutter die 128. There may be minor gradients in this first general state of tension T₁, e.g., as the sheet product web 102 passes from the reel 104 to the roller 110, from the roller 110 to the printer 112, from the printer 112 to the design die cutter roller 118/anvil 120 system and from the design item-creating die cutter roller 118/anvil 120 system to the lateral die cut roller 126/anvil 127 system. None of these minor tension gradients (if any there are) in the overall first general state of tension T₁ should be sizeable enough to produce a vertical “hump” in the sheet product web 102 and/or create a strain or tear in the materials from which that web 102 is made.

[0031] Upon leaving the die cutter roller 126/anvil roller 127 system, the leading edge 134 of a given sheet is directed into a downstream sheet handling system. This downstream sheet handling system is separated from the die roller 126/anvil roller 127 by a gap 129. This downstream sheet handling system is preferably a roller system comprised of a top roller 136 and a bottom roller 138 so adapted and arranged that they form a nip into which the leading edge 134 of any given cut sheet is directed after it leaves the die cutter roller 126/anvil roller 127 system. FIG. 2 also depicts a particularly preferred embodiment of this invention wherein an air current 140 (or air blast) is delivered to the bottom of each newly cut sheet in order to direct the leading edge 134 of that new cut sheet into the nip of the top roller 136/botton roller 138 system.

[0032] A very generalized scrap take up reel 125 is shown taking up scrap created by any previous cutting operations—and especially any scrap created by trimming the forward edges of the sheet product web 102. For example, a scrap matrix 127 is shown being removed from the process after it passes through the lateral cut die roller 126/anvil roller 130 system. Scrap 131 created by the die cutter roller 118/anvil roller 120 system and/or by any trimmer or cutter (not shown) also is removed from the overall process 100. This scrap matrix 131 could be directed to another scrap take up reel (not shown) comparable to scrap take up reel 125. It also should be appreciated that all such scrap can be removed from the process shown in FIG. 2 by completely different means. For example, in a particularly preferred embodiment of this invention scrap (127 and/or 131) is removed from the manufacturing process 100 by a vacuum suction-based scrap take up device such as that illustrated in FIG. 3 as item 204.

[0033] In yet another particularly preferred embodiment of this invention, the nip defined between downstream top roller 136 and bottom roller 138 not only receives the newly cut sheet, it also receives a web 142 of a bottom pouch layer material. This bottom pouch layer web 142 is shown being dispensed from a supply reel 144. The top surface 146 of the bottom pouch layer web 142 may be (or may not be) provided with a layer of adhesive 148. If used, such a layer of adhesive 148 comes into adhering contact with the bottom side 116 of the lower sheet product layer 108 and thereby creates a three layered, intermediate product web 150. This intermediate product web 150 is comprised of an upper sheet product layer 106 component, a lower sheet product layer 108 component and a bottom pouch layer 142 component.

[0034] This three layered intermediate product web 150 is then contacted with a top pouch layer 152. This top pouch layer 152 is dispensed, in the form of a web 154, from a dispensing reel 156. In effect this web 154 is placed over the upper sheet product layer 106 that contains the subject sticker type cut out designs. To this end, the top pouch layer web 154 is preferably fed into a nip created between roller 158 and roller 160. This process creates a four layered intermediate web 162. As can be seen in FIG. 4, passage of the three layered intermediate product web 150 and the top pouch layer web 154 through the roller 158/roller 160 nip (to create the four layered intermediate web 162) also may serve to place the edges of the top pouch layer web 154 in forced contact with the adhesive 148-carrying edges of the top side 146 of the bottom pouch layer web 142. This action serves to create the sealed edges of the final product pouches or packages of this patent disclosure. In an alternative embodiment of this invention, the bottom pouch layer is not provided with a layer of adhesive. In this case, the respective abutting edges of the top pouch layer and the bottom pouch layer are joined by a heat fusing operation well known to the packaging arts. If yet another embodiment, the bottom side of the top pouch layer 152 may be supplied with a layer of adhesive material.

[0035] In any case, the four layered intermediate web 162, then is delivered to one or more roller devices that perform various other operations upon said intermediate web 162. One of these operations can be a slitter operation wherein the adhesive bound edges of the top pouch layer 152 and the bottom pouch layer 142 are trimmed in a longitudinal direction. For reasons hereinafter more fully explained, such a edge trimming operation constitutes part of a preferred embodiment of this invention wherein the width of a top pouch layer web 152 is greater than the counterpart width of an adhesive-bearing bottom pouch layer web 142. The top pouch layer's greater width assures that any adhesive bearing edges of the bottom pouch layer (that extend beyond the edges of the sheet product) are delivered to the 136/138 roller system completely covered by the wider top pouch layer web 152. This edge overlapping circumstance is illustrated in the perspective views shown in FIGS. 3 and 4.

[0036] By way of example only, FIG. 2 also shows that the longitudinal slitting or edge trimming operation carried out on the lateral edges of the four layered intermediate product 162 can be carried by a die roller 164 having longitudinal knife edge(s) 166. The respective locations of the longitudinal slits made by such a knife edge 168 are shown in FIG. 7. The roller 164 also may be supplied with other tools such as, by way of example, a perforator tool 168. FIGS. 7 and 8 respectively show the location and purpose of the perforations made by such a perforation tool 168. FIG. 2 also suggests that the perforation of the top pouch layer 106 and/or the bottom pouch layer 108 may be carried out by a separate and distinct perforator tool. Such a tool is very generally depicted by an upper perforator roller 172 and a lower perforator roller 174.

[0037] This roller system 172/174 also may also be provided with one or more dies 176 to cut holes for wire holders used in store display racks. Two such holes 177 and 179 are shown in FIG. 7. FIG. 2 also shows a take up reel 178 taking up scrap material 180 created by the previous cutting operations. Like scrap take up reel 125, scrap take up reel 178 may be replaced by a suction type take up system such as that depicted in FIG. 3 as item 204. It also should be appreciated that any of these roller devices 158/160, 164/170, 172/174 (or a separate and distinct heater tool device) may also be tooled to deliver heat to certain edge regions of the top pouch layer/bottom pouch layer interface in or to heat fuse these regions together and thereby create a pouch or package in which a sheet product resides.

[0038] Be that as it may, a final cutting operation is shown being carried by a cutter roller 182/anvil 184 system. In the alternative, the adhering top pouch layer/bottom pouch layer existing between successive sheet products may be laterally perforated and wound up on rolls suitable for merchandising the end products. Be that as it may, the cutter roller 182 depicted in FIG. 2 is shown equipped with a die 186 capable of completely cutting through the top pouch layer web 152 and bottom pouch layer web 142. This cutting operation is carried about half way between successively spaced sheet products as seen in FIGS. 5 and 6. Thereafter, the final products are delivered to a final product collection device such as the conveyor 188 shown in FIG. 2.

[0039] It also should be noted that the bottom pouch layer web 142 receives the top layer web 154 while the bottom pouch layer web 142 (and any other webs associated with it) are in a second general state of tension T₂ that generally exists over the distance 133 depicted in FIG. 2 between roller system 136/138 and lateral cutter die 186. Other rollers (not shown) also may be instrumental in creating tension T₂ (and/or tension T₁). Here again, there may be minor gradients in this second general state of tension T₂, e.g., as the bottom pouch layer web 152 (and any other web thereafter associated with it) passes from rollers 136/138 to rollers 158/160, to rollers 164/170, to rollers 172/174 to rollers 182/184. Here again, no minor tension gradient (if any there are) in the overall second general state of tension T₂, should be sizeable enough to produce vertical “hump” in the intermediate sheet product webs 150 and 162 and/or be sizable enough to create a strain or tear in the materials from which these respective webs are made.

[0040] Next, it should be noted that one particularly preferred method of keeping the second tension T₂ substantially uniform over the distance 133 is through use of succeeding rollers (preferably, the powered roller of any given roller pair) whose diameters are successively slightly larger in diameter in the downstream direction of the process 100. For example, a roller system wherein roller 160 is slightly larger in diameter than roller 138, roller 170 is slightly larger than roller 160 and so on through roller 184 may be employed to keep tension gradients in the second tension T₂ (existing over the distance 133 between roller system 136/138 and roller system 182/184) to a desired level. Finally, it should also be noted that tensions T₁ and T₂ can be made substantially equal to each other; they may or be made substantially different (e.g., through use of the above mentioned rollers having increased diameters) according to changing manufacturing operating parameters and/or esthetic desires with respect to different kinds of feedstock materials.

[0041]FIG. 3 depicts (in a perspective view) certain distinct aspects of the overall manufacturing method illustrated in FIG. 2. The first aspect involves the cutting of one or more designs in the upper sheet product layer 106 of web 102. This cutting process is characterized by the fact that the die 122 used to cut these designs into the upper sheet product layer 106 is only thick or deep enough (see item 124) to penetrate into the upper sheet product layer 106 to a depth that generally corresponds with the thickness 190 of that upper sheet product layer 106. In other words, the die 122 does not penetrate into the lower sheet product layer 108. Thus, the subject designs are cut into—and hence can be removed from—the body of the upper sheet product layer 106.

[0042] The second aspect of the manufacturing method illustrated in FIG. 3 involves cutting separate and distinct sheets from the sheet product web 102 after a design pattern has been cut into the upper sheet product layer by die 122. This sheet cutting process is characterized by the fact that a second die (i.e., die 128) shown in FIG. 3 cuts completely through both the upper sheet product layer 106 and the lower sheet product layer 108. In other words, the second die 128 makes a complete, lateral cut that creates a series of separate and distinct sheet products (e.g., sheets 102A, 102B, etc.). FIG. 3 illustrates this circumstance by showing a first separate and distinct sheet product 102A completely separated from the sheet product web 102 existing on the left side of the die 128. These individual sheets 102A, 102B, etc. are cut from the feedstock web 102 in a sequential manner such that a distance 192 separates successive cut sheet products 102A, 102B, etc. into some desired uniform length.

[0043] These sheet products are then sent over the gap 129 between rollers 126/127 and rollers 136 and 138. Preferably, an air current is directed at the bottom of each cut sheet as it crosses over between the two roller systems. Thereafter, the underside 116 of each successive cut sheet product is placed in contact with a bottom pouch layer 142 whose top side 146 is preferably (but not necessarily) provided with a layer of adhesive material 148. In one particularly preferred embodiment of this invention, the action of roller 138 and roller 136 (see FIG. 2) causes the bottom pouch layer 142 to adhere to the bottom 116 of the web 102 in a circumstance wherein the width 194 of the bottom pouch layer 142 is (but not necessarily must be) greater than the width 196 of the web 102. Hence the bottom pouch layer 142 will overlap the web 102 by a distance 198 and 198′ on its respective sides. Preferably, these two overlapping distances 198 and 198′ will be substantially equal. The resulting physical relationship between the bottom pouch layer 142 and successive cut sheet products 102A, 102B, etc. are such that exposed areas of adhesive 148 exist after the bottom pouch layer is adhered to the bottom 116 of the cut sheet products. For example, FIG. 3 depicts a layer of exposed adhesive 148A between sheet product 102A and sheet product 102B. Another layer of exposed adhesive 148B exists on the right edge region 200 of the bottom pouch layer 142. A comparable layer adhesive 148C is on the left edge 202 of the bottom pouch layer 142. As will be seen in subsequent portions of this patent disclosure, these exposed areas of adhesive 148A, 148B, 148C, etc. are placed in contact with the upper pouch layer 154 to create the sealed package in which the individual cut sheet products 102A, 102B, etc. reside.

[0044]FIG. 3 also depicts a preferred embodiment of this invention wherein a suction device 204 is used to remove scarp matrix from any previous cutting operations. For example, a die cutter may create web scrap that must be removed from the overall manufacturing process 100. Such scrap 127 may be removed from the process by a take up reel 125 such as that shown in FIG. 2, or by the suction device 204 shown in FIG. 3. In any case all such scrap removed by such a suction device 204 is very generally suggested by upwardly directed arrows 127′.

[0045]FIG. 4 depicts a top pouch layer 154 being placed over the top surface 114 of a given cut sheet product 102A. This top surface 114 shows an array of sticker items (e.g., baseball design 151, star 153 and triangle 155) that are cut into the upper sheet product layer 106. The top pouch layer 154 is shown with a width 208 that is preferably greater than the width 194 of an exposed adhesive bearing bottom pouch layer 142. This overlap is depicted as right side overlap distance 210A and left side overlap distance 210B. Thus, when the top pouch layer 154 and the adhesive bearing bottom pouch layer 142 are pressed together by the action of roller 158 and roller 160 (see FIG. 2) these two pouch layers adhere to each other in the exposed adhesive bearing areas 148A, 148B, 148C, etc. to form a sealed pouch around each successive cut sheet product (e.g., around sheet product 102A of FIG. 4). The overlap assures that no adhesive is left uncovered—and hence inclined to create clogs in the process.

[0046]FIG. 5 is a plan view of the four layered intermediate product 162 existing in the overall process depicted in FIG. 2. A series of cut product sheets 102A, 102B, 102C, etc. are shown residing under the top pouch layer 154. These cut sheet products are preferably spaced from each other by a regular distance 192. A cut line 212 is depicted about midway between the cut sheet products 102A and 102B. This line represents the location of the cut to be made by the cutter die 186 when the four layered intermediate product 162 is cut into a series of final packaged products 102A(F), 102B(F), 102C(F) and so on. These final packaged products are removed from the overall manufacturing process by some package conveying/collection device such as the conveyor device 188 shown in FIG. 2. In an alternative embodiment of this invention, the final products are not cut into completely separate and distinct packages, but rather remain in the form of a continuous final product web that is rolled up into a roll from which individual packages are torn at the time of sale to the end user. To facilitate the tearing of such individual packages (e.g., the package containing sheet product 102D) from the four layered web 162, a perforation line 212A (rather than cut lines 212) is depicted between the packages containing cut products 102C and 102D. FIG. 5 also illustrates the region 214 in which the top pouch layer 154 and the bottom layer 142 are forced to adhere to each other (e.g., by the action of a layer of adhesive on the top surface of the bottom pouch layer, or by the action of a heater tool that forms a component of a pressure roller system).

[0047]FIG. 6 is a cross sectional view as seen from section 6-6 of FIG. 5. The four layered portion 162 of the overall web 216 has a top pouch layer 154, upper sheet product layer 106, lower sheet product layer 108 and bottom sheet product layer 142. The depressed region between successive sheet products 102A, 102B, etc. is comprised of a ply of the top pouch layer 154 and a ply of the bottom pouch layer 142. These two plys or layers are bound together by the adhesive layer 148 existing on the top surface of the bottom layer 142 and/or by the action of a heater tool and/or by the presence of adhesive on the bottom surface of the top pouch layer 154. FIG. 6 also depicts a layer of ink 122′ placed on the top surface of the upper sheet product layer 106. The upper sheet product layer 106 is shown with depth cut marks 151′, 153′, 155′ etc. that define the depth of the cut made by the design die cutter component 122. These cuts also generally coincide with the outline of the designs (see design items 151, 153 and 155 in FIG. 4). FIG. 6 also illustrates (1) the distance 192 between the cut sheet products 102A, 102B and 102C, (2) the distance 214 over which the top and bottom layer materials adhere to each other, (3) the location 186′ of the cuts to be made by the cutter 186 and, in the alternative, (4) the location of lateral perforation lines 186′ such as those labeled 212A in FIG. 5 (if they in fact are employed).

[0048]FIG. 7 is a plan view of an intermediate product 162 sheet product/pouch system made according to the teachings of this patent disclosure. This figure, among other things, shows the locations of certain sheet overlapping and cutting operations carried out with respect to the intermediate sheet product/pouch system. The sheet product 102B itself is shown surrounded by a pouch perimeter region 216 created when the top pouch layer 106 and the bottom pouch layer 108 are forced to adhere (or are heat bonded) to each other around the perimeter of the sheet product 102B. As is also seen in FIG. 3, the width 194 of the bottom pouch layer 142 shown in FIG. 7 is greater than the width 196 of the sheet product 102B. The right hand overlap is depicted by distance 198. The left hand overlap distance is labeled 198′. FIG. 7 also illustrates another preferred embodiment of the present invention (also shown in FIG. 4) wherein the top pouch layer 154 has a width 208 that it is wider than the width of the bottom pouch layer 142. The right top pouch layer overlap distance is labeled 210A. The left overlap distance is labeled 210B. The presence of these top pouch layer overlaps assures that all exposed adhesive (e.g., 148B, 148B′ and so on, if any there be) on the edge regions of the bottom pouch layer will be completely covered by the top pouch layer 154. Thus, malfunctions that may result from the presence of exposed adhesive are prevented. Such edge overlap 210A, 210B, etc. regions are not, however, esthetically pleasing. Therefore, in a particularly preferred embodiment of this invention, a right side longitudinal slit line 218A and a left side longitudinal slit line 218A′ are made in the adhering edge regions of the intermediate product 162. These slits create a clean cut (and hence esthetically pleasing) edge along the two sides of the final product package. FIG. 7 also shows the location of a perforation line 220 in at least one of the four sides of the finished product package and the location of holes 177 and 179 for receiving store display hangers. This perforation line 220 preferably lies inside the regions (e.g., region 218) where no adhesive 148B resides.

[0049]FIG. 8 depicts a preferred method of opening the sheet product/pouch systems of this patent disclosure. To this end, a finished product package 102B(F) is shown being torn open along perforation line 220. That is to say that a tab 222 is shown being torn away from the right edge region 224 of the finished product package. This tearing action can be (but need not be) facilitated by the fact that the perforated line 220 is inside a sealed edge perimeter 216 of a top pouch layer/bottom pouch layer sealed region 218 wherein adhesive is found. Thus, the tear takes place along a line 220 where the top and bottom pouch layers do not adhere to each other. In either case, when the tear is completed, a sheet product 102B can be readily reached by a human hand.

[0050] Although the preceding disclosure sets forth a number of embodiments of the present invention, those skilled in this art will however appreciate that other arrangements or embodiments, not precisely set forth, could be practiced under the teachings of the present invention. Therefore, the scope of this invention should only be limited by the scope of the following claims. 

Thus, having disclosed this invention, what is claimed is:
 1. A method for producing a premium product/pouch system, said method comprising: introducing a premium product web into a machine capable of: placing the premium product web in a first state of tension, cutting an individual premium item from the premium product web; guiding the individual premium item into a downstream web handling system; associating the individual premium item with a web of bottom pouch layer; providing the individual premium item with a web of top pouch layer; placing the bottom pouch layer in a second state of tension; and creating a pouch from the web of bottom pouch layer and the web of top pouch layer.
 2. The method of claim 1 wherein the premium product web is a two ply sheet system.
 3. The method of claim 1 wherein the premium product web is a single ply sheet.
 4. The method of claim 1 wherein the premium product/pouch system is provided with holes to receive store display hangers.
 5. The method of claim 1 wherein the sheet product web is comprised of an upper sheet product layer and a lower sheet product layer that adhere to each other by use of a releasable adhesive placed on a bottom side of the upper sheet product and wherein an array of stickers is cut into the body of the upper sheet product layer.
 6. The method of claim 1 wherein the sheet product web receives printing on its top surface.
 7. The method of claim 1 wherein the sheet product web receives printing on its top surface and on its bottom surface.
 8. The process of claim 1 wherein the individual premium product is guided to the downstream web handling system through the aid of an air current delivered to an underside region of the premium product.
 9. The process of claim 1 wherein the web of top pouch layer is wider than the web of bottom pouch layer.
 10. The process of claim 1 where scrap is removed from the process by a suction system.
 11. A method for producing a two-ply sheet sticker product/pouch system, said method comprising: introducing a two-ply sheet product web into a machine capable of: placing the two-ply sheet sticker product web in a first state of tension, printing upon the two-ply sheet sticker product web while it is in the first state of tension; die cutting at least one design in a top layer of the two-ply sticker product web; cutting an individual two-ply sheet sticker product sheet from the two-ply sheet sticker product web; guiding the individual two-ply sheet sticker product sheet into a downstream sheet handling system; associating the individual two-ply sheet sticker product sheet with a web of bottom pouch layer; providing the individual two-ply sheet sticker product sheet with a web of top pouch layer; placing the web of bottom pouch layer in a second state of tension; and creating a pouch from the bottom pouch layer and the top pouch layer.
 12. The method of claim 11 wherein the sheet product web is comprised of an upper sheet product layer and a lower sheet product layer that adhere to each other by use of a releasable adhesive placed on a bottom side of the upper sheet product layer.
 13. The method of claim 11 wherein the sheet product web receives printing on its top surface.
 14. The method of claim 11 wherein the sheet product web receives printing on its top surface and on its bottom surface.
 15. The method of claim 11 wherein the sheet product web is comprised of an upper sheet product layer and a lower sheet product layer and wherein designs are cut into the upper sheet product layer to create stickers.
 16. The process of claim 11 wherein the individual premium product is guided to the downstream web handling system through the aid of an air current delivered to an underside of the premium product.
 17. The process of claim 11 wherein the web of top pouch layer is wider than the web of bottom pouch layer and wherein the web of bottom pouch layer further comprises a layer of adhesive.
 18. The process of claim 11 where scrap is removed from the process by a suction system.
 19. The process of claim 11 wherein a top surface of the bottom pouch layer is provided with an adhesive.
 20. A two-ply sticker product in a package having a perforation line located between a sheet product and an outer edge and wherein a top pouch layer and a bottom pouch layer adhere to each other to create the package in which the two ply sticker product resides. 